Method of making milling-cutters



F. MULLER.

METHOD OF'MAKING MILLING CUTTERS. AP PLICATION FILED DEC.26, 19H 1 348 291 Patented Aug. 3, 1920.

2 SHEETSSHEET I.

| Gave to:

WNW/

F. MULLER.

METHOD OF MAKING MiLLING CUTTERS.

APPLICATION HLED DEC. 26. 1918.

Patented Aug. 3, 192 0.

2 SHEETS-SHEET 2.

5] mucwfot entree stares IEilLLEPJ, Ii:.I-t .iFGltD, CUNl IECTICUT. ASSIGNOR TO PRATT & WHITNEY PATENT OFFICE.

COMEABTY, 0F KE N YORK, N. Y., A CORPORATION OF NEW JERSEY.

eas es.

. THGD MAKING MILLING-CUTTERS.

Specification of Letters Patent.

Patdnted A11 3, 1920.

Original application. filed may 1, 1918, S rial No. 231.796. Divided and this application filed December 26,

To all whom it may concern. 7

Be it known that l, l 'ninnnnioir IHULLER, a citizen of the United States, reslding at Hartford, in the county of l'l artlord and State of Connecticut, have invented certain new and useful Improvements in Methods of Making hLlilling-Cutters, of which the following a specification.

It is a well known principle in the art of cutting metal rat the cutting edge of the tool should p erably be inclined with respect to the direction of relative movement so to eli'ect a shearing cut. This inclination is 'of advantage in that it improves the cutting and in is also of advantage in that it oermits the tool to engage the work gradually and with relatively little shock instead of engaging it suddenly with greater shook. lhis principle has been applied to relieved milling cutters which are of uniform dian'ietcr tl'iroughout and has also been applied to milling cutters having a uniform taper from one end to the other. These niillin cutters have their cutting edges longitudinally inclined with respect to the the cutting edge usually approximately conforming to helix. Thus each tooth is enabled to engage the work gradually and to eitect a shearing cut.

I have applied this principle to accurately made and properly relieved formed or contour cutters. ter 1 mean one in which the diameter varies from end to end in ways differing from a uniform taper, the cutter being thus adapted to cut a predetermined contour other than a straight line. Prior to my invention it had not been deemed practical or possible to make such cutters with inclined cutting faces. The said invention is presented and claimed in my copeuding application for milling cutters, Serial No. 268,349, filed on even date herewith.

In my copending application for methods of making milling cutters, Serial No. 268,350, filed on even date herewith, l have presented a method of makingcutters em-v a formed or contour eut- Serial No. 268,351.

and specifically claim one of the said variations of the method presented in the said application Serial No. 268,350. The specific tion set forth in the aforesaid application,

Serial No. 268,349, {ind-I have illustrated two ways in which the method may be practised. It will be understood, however, that the drawings are for illustrative purposes only and are not to be construed as defining or limiting the scope of the invention, the

accompanying claims being relied upon for that purpose. It will be particularly understood that the contour of the cutter shown has been selected merely by Way of example and that any practical contour may be substituted for that illustrated.

Of the drawings:

Figures 1 and 2 are plan and end views respectively of a formed milling cutter such as may be made in accordance with the invention.

Figs. 3 and d are enlarged fragmentary diagrammatic plan and end views respectively of the milling cutter shown in Figs. Land 2. In these views there is shown a smaller number of teeth and the inclination of the cutting faces and therelief are increased in order to bring out the principles oi the invention more clearly.

Fig. 5 is a diagrammatic View illustrating certain features of the cutter shown in Figs. 3 and 4-.

Figs. 6 and 7 are end and bottom views respectively of a preliminary milling cutter which may be used for milling the final milling cutter shown in Figs. 1 and 2.

Fig. 8 is a plan view of a lathe tool adapted to be used for shaping the preliminary cutter.

Fig. 9 is an enlarged fragmentary diagrammatic end view of a preliminary cutter somewhat different from that shown in Figs.

6 and 7, but' which may also be used for milling the final'milling cutter. The cutter is shown as having a smaller number of teeth and as having increased inclination and re lief in conformity with the increased inclination and relief shown in Figs. 3 and 4.

' milling cutter shown in different lathe tool.

"s'vith the increased inclination and relief 1gcnerally helical in form This View also illustrates the, lathe tool shown in Fig. 8 in operative relation to the preliminary cutter.

Figs. 10 and 11 are views similar respectively to Figs. 8 and 9 but lllllSlFl (Band 7 and a Figs. 19; and 13 are enlarged diagrammatic end and bottom views respectively oi the preliminary milling cutter shown in Figs. 6, 7 and 11. The cutter is shown as having a smaller number of teeth and as having ncreased inclination and relic" in conform 1 shown'i'n Figs. and l. Fig. M is a diagrammatic view illustrating certain features of thccuttcr shown in Figs. 12 and 13.

Fi 15 is a diagrammatic View illusrating t -e preliminary cutter shown in Figs. 12

v and 13 in use for milling a blank for the final cutter, the milling operation having been started but not finished.

tion. Referring particularly to l to 5 of the drawings, it will be seen that l have shown a cutter A which is shaped to cut a predetermined contour dillcring from a straight line. The cutter 1s provided with a pluralityof generally longitudinal teeth '1 between which are grooves 2, the teeth and grooves being preferably spaced uniformly. The grooves 2 between the teeth can be of any usual or preter'rcd depth and shape, as

required by the spacing and by the depth of the contour to be out.

The -front wall 3 of each tooth 1 constitutes the cutting face thereof and this cutting face is radial or approximately so in order to provide asatisfactor cutting angle. Each cutting face 3 is inc ined or positioned obliquely so that v its longitudinal lines lie at angles to the axis Preferably, each tooth ..L is

nd each cutting face 3 conforms to a hel icoid. As illustrated, thch'elicoid is one "formed by a genof the cutter.

eratrix'following the axis of the cutter andalso following a helix on a cylinder concentrio with the axis thereof, the helicoid in this case being radial. The teeth and the cut-.

tin faces may be inclined in either direction an the de rec of inclination may be 'YZM'IBfl as require The cutter may bemade for cutting any desired practical contour. The contour may be made up of a series of s raight lines, or a series of circular arcs, or a combination of circular arcs and strai 'ht lines, or the conning the spcctour may consist in-whole or in partof noncircu-lar curves. T he cutter shown is adapted for cutting a contour consisting of plicable however for making a cutter having acurrcd contour. v

The outer edge of each cutting "face 3 has an outline which is adapted to out the predetermined contour when the cutter is ro-- tated, this outline of the cutting face following the helicoidal surface thereof. In other words the outer cutting edge of each face is 01 such form that the projection of the said edge about the axis of the cutter uponan axial plane of intersection is the same as the predetermined contour to be cut. This will be more clearly understood from the diagrammatic views in Figs. 3 and For the particular contour illustrated, the four points l, 5, 7 and 8 on the'outline of the cutting face are all at equal distances from the axis of the cutter; the central point 6 is at a distance from the axis which is less by the distance 6 and all other points along the outline are at their respective co 'rect distances from the center so that when the cutter is rotated they will define the correctpre determined contour, as shown, by full lines in Fig. 5. This relationship of the, several points along the outline of the cutting face obtains notwithstanding the fact that the cutting face is a' warped or helicoidal surface,

Each tooth of the cutter is relieved along lines 9 extending backward and inward from the outline of the cutting face, these relief lines forming a continuous surface or con; tinuous surfaces which extend from end to end oi the cutter. The relief lines are properly constructed notwithstanding the variations in radius at different points along the said outline and notwithstanding the variations in angular position resulting from the warped or helicoidal cutting face. Preferably the relief lines 9 are maintained in similar relationship to each other as they extend backward and inward, the lines conforming to spirals of Archimedes. The result is that .each tooth of the cutter, at any axial plane of intersection, such as 5: has a distorted shape, as shown by dotted lines in Fig. This distorted shape includes points '14, 15,. 16, 17 and 18 corresponding respectively to the points 4 5, 6, 7 and 8 onlthc outline of the cutting race. The distortion of shape results from the fact that the successive inward inclined reliei lines 9 start at different angular posi ions because of the inclinedor helicoidal cutting face. Therefore with the cuttin face inclined in the direction illusas they extend backward and inward, as is preferred, it possible to sharpen or grind teeth of the cuttcron the front cutting faces 3 without changing the effective contour. The teeth present the same effective contour at successive inclined surfaces of intersection similar in form and position to the initial cutting faces 3. face, such as c.-c, back of an initial cutting face 3, and similar to the said face, the same effective contour will be found. Therefore if the teeth are ground on their front faces to helicoids which are the same as the helicoids of the initial cutting faces the fective contour will remain the same.

Taking up now the method of making the milling cutter, it will be understood that the preliminary steps of turning the blank, cutting the grooves therein, etc, can be carried on in any usual or preferred way, these not of themselves constituting any part of the present invention. The particularly to the method of shaping the blank to provide distorted shape which will enable it t i cut acorrect contour.

in accordance with the general method set forth in my aforesaid copending application, Serial No. 268,350, the shape of the cutter to be ma do is formed by means of a preliminary milling cutter, this preliminary cutter preferably acting directly on the final cutter. Figs. and 7 show a preliminary milling cutter U such as may be used. The cutter U is formed with teeth 19 having grooves 90 between them. As set forth in the said application, each tooth 1.9 of the preliminary cutter is formed with a heli- .coidal cutting face Ell having a longitudinal pitch bearing predetermined ratio to the .gitudinal r'tch of the helicoids of the l cutter Di and each tooth is provided degree of relief of the teeth of the final cutter. In the said application I havev stated that it is in many cases more convenient to make the pitches of the helicoids the same At any surinvention relates i relief lines 9-2 having a degree of relief bearing the same predetermined ratio to the dition that may lead to such a departure. In Fig. 8 I have shown diagrammatically a cutterS having teeth 23 with grooves 24 between them and having helicoidal cutting faces 25. For clearness of illustration the inclinationof the cutting faces and the relief are increased as in Figs. 3 and 4t. The cut ting faces 25 are constructed with a longitudinal pitch the same as that of the helicoidal faces 3 of the teeth of the final 'cutter A. The teeth23 are provided with relief lines 26 which are constructed with the same degree of relief as the relief lines 9 of-thev teeth of the cutter A.

The preliminary cutter can most conveniently be made by means of a lathe tool such as V, shown in Figs. 8 and 9, this tool being used in a relieving lathe. The-lathe tool V is formed with its top cutting face 2? having a contour P, 5", 6", 7", 8" which is the same as the effective contour 4, 5, 6, 7, 8 of the teeth of the final cutter A. In order to make a small correction, as explained in detail in my aforesaid application, the tool V is preferably set with its top cutting face in a plane at an angle to a plane through the axis of the preliminary cutter, as indicated in Fig.8. When the preliminary cutter S is bein formed, it is rotated in the direction of the arrow, the tool V being moved in and out, as indicated by the horizontal arrow, so as to follow the proper relief lines 26. Inasmuch the relief lines 26 conform to the same spirals as the relief lines 9 of the cutter A, it is obvious that the actual v t angle or intersection between the relief lines and the circumferential lines is considerably greater for the cutter S because of the smaller radius thereof. For-the cutter A the relief angle is d as shown in Fig.4, and the cutter S has a considerably-larger angle d". The lathe tool V must 'have its front face '28 formed at an angle f, somewhat greater than the angle 02*, so as to properly clear the inclined relief lines 26. lVith the cutter S provided with relatively great rclief, as shown in Fig. 8, the angle f must be large, and in fact, the inclination of the front face 28.0f the tool may be so great as to seriouslyinterfere with the proper support of the cutting edge of the tool. When a this is the case the tool V can be modified by reducing the amount of reliefon the preliminary cutter.

Fig. 10 is a view similar to Fig. 8, but showing the cutter U. The helicoidal front cutting faces 21 of the teeth 19 have a longitudinal pitch which is considerably less than the longitudinal pitch'of the helicoidal faces 3of the teeth of the cutter A. As shown this pitch of the hclicoidal faces21 1s exactly one-half the pitch of the helicoidal faces 3. The degree of relief of the lines 22 is considerably less than the degree of relief of the cutter A. When the pitch of the helicoidal cuttin faces is exai tly one-hall as shown, the degree of relietis also exac't'ly'one-halt, the relief angle being cl.

The preliminary cutter U can be made by means of a lathe tool W, which has a top.

face 30 is considerably than the angle of the 'front face 28 of the tool V. This is made possible because of the considerably smaller relief angle cl on the cutter U t will seen that by reducing the pitch and the relietas shown, it becomes possible to use a better and more satisfactory initial lathe tool. The cutter U is more completely shown in Figs. 12 and i l. Each tooth of the cutter U has at any longitudinal plane of intersection such as l4-14l a shape which is the same or approximately the same as the predetermined contour to be cut by the cutter A. This is indicated by dotted lines in Fig. 14, the points l, 5, 6, 7 and 8 corresponding respectively to the points l, 5, 6, 7 and 8 on the eltective contour of the final cutter A.

As already stated, thehelicoidal cutting face 21 of each tooth 19 has a longitudinal pitch less than that of the helicoidal faces 3 of the teeth of the final cutter. The relief of each tooth is also less thanthat of the relief of the teeth of the final cutter. The ratio between the two pitches is the same as the ratio between the two reliefs, and as shown. each ratio is one to two. The pitch of the helicoids of the preliminary cutter is one-hall that of the helicoids of the final cutter and the relief of the teeth is also one-half.

. Referring back to Figs. 3 and 4 it will be noted that for a given length 2' along the cutter A there is a corresponding angular advance The actual linear advance of one end of the cutting face with respect to the other at the outside radius is represented by l". At a smaller radius the angle 9' is the same but there is a smaller linear advance I. For the same length i along the cutter U there is an angle j which is twice the angle j. and there is a linear advance Z which is twice the advance I at the same radius on the cutter A. It will be noted that for an angle m of the cutter A there is a decrease in radius n, the relief angle being (Z as alread noted. For

the same angle m there is a ecrease in radius a, which is one-half the decrease n for the cutter A. The relief angle d is less than the angle d and is also less than the angle a? of the cutter S as already noted. As the result of providing the preliminary cutter U with helicoidal cutting faces and.

with the relief as shown and described, the

contour of each cutting face is distorted. the

v 1 I G extent of distortion being the same in slowly amount as that of the final. cutter at an axial plane of intersection as shown b dotted. lines in Fig. 5. As shown by'full lines in Fig. 14: the distorted contour of the cutter U has points 14, 15, 16, 17 and 18 corresponding respectively to the points 4, 5, 6, 7 and 8. The several points l5, l6, 'lTand 18 to the right of the point l or 14; are spaced outward from the respective points 5, 6, and8 b progressively increasing distances. This distorted contour is the same irrespective of the actual pitch and relief, provided the pitch and relief are always in the same ratio to' the pitch and relief of the final cutter.

In Figs. 15 and 16 I have shown the cutter U being used forshaping a blank to form the cutter A. It will' be understood that the cutter U is rapidly rotating in the direction indicated by the arrow thereon; that 8.5 the blank is slowly rotating in the direction indicated by the arrow thereon; and that relative approaching and receding move ments are eliected between the cutter and the blank in timed relation to the blank r0 tation to provide the required relieton the final cutter. These relieving movements are preferably effected by moving the axis of the cutter bodily toward the axis of the blank, its-indicated by the vertical arrow, and then bodily away from the axis of the. blank in the opposite direction. Preferably the downward or inward relieving movement is so timed that the resulting relief on the blank will conform to spirals of Archi-' modes. The cutter U is moved slowly downward during the cutting of each tooth "and then is rapidly moved upward between the teeth to position it for the cutting of the next tooth.

As shown in Fig. 15, the cutter U and the blank have been so adjusted that the teeth of the rotating cutter will mill the initial point 4015 the with of the blank A to the required distance from the axis. The downward movement of the cutter U in timed relation to the slow rotation of the blank causes it to take a cut which gradually increases in depth at the successive points back of the point 4. As the-cutter blank A- is turned and as the cutter U is fed downward in accordance with the relief, the parts move to the positionshown in Fig. f 16, the distorted shape of the 'cutter U-ex actly compensating for the distortion which would otherwise talke place in the shape of the cutter A. The cutter U shapes the cutter A with the several points 4, 5,6, 7 and 8 all at the proper distances from the axis, so thatthe cutter A when used will generate the true contour, as shown by full linesiri I l1 ig. 5. r

In order to illustrate the fact that the pitch and relief ofthe preliminary cutterneed not be less than those of the final cute 130 ter, but may in fact be greater, I have shown a different preliminary cutter Z in Figs. 17 and 1.8. The cutter has teeth 31 with grooves 32 between them, and the teeth are provided with helicoidal cutting faces 83. At an axial or approximately axial longitudinal plane of intersection such as 1 l-14:, the cutter has a shape which is the same as the shape 4, 5, 6, 7, 8 of the cutter U shown by dotted lines in Fig. 14. The helicoidal cutting face 33 of each tooth 31 has a longitudinal pitch greater than that of the helicoidal faces 3 of the teeth of the final cutter. The relief of each tooth is-also greater than that of the teeth of the final cutter. T he ratio between the two pitches is the same as the ratio between the two reliefs, and as shown each ratio is four to three. The pitch of the helicoids 0f the preliminary cutter is one and one-third times that of the helicoids of the final cutter and the degree of relief of the teeth is also one and one-third times that of the teeth of the final cutter.

For a length 2' along the cutter Z there is an angle j which is three-fourths the angle 7', and there is a linear advance Z which is threefourths the advance 2. For the angle m there is a decrease in radius n which is four-thirds or one and one-third times the decrease n. The relief angle is d", this being greater than the angle (1 of the cutter A and also greater than the angle (Z of the cutter S.

Each cutting face of the cutter Z has a distorted effective contour 14 15, 16, 17". 18" which is the same as the contour 14, 15, 1U", l7, 18 of the cutter U, as shown. by full lines in Fig. 14. The cutter Z can be used in the same way as the cutter U, as shown in Figs. 15 and 16.

\Vhat I claim is:

1. The herein described method of snaping a spirally relieved milling cutter adapted to cut a predetermined contour other than a straight line and having helicoidal cutting faces, the method consisting in forming a preliminary milling cutter having at axial planes of intersection a shape the same or approximately the same as the predetermined contour and having its teeth provided with helicoidal cutting faces with a longitudinal pitch different from the longitudinal pitch of the helicoidal cutting faces of the final cutter and provided with a degree of spiral relief different from the degree of spiral relief of the teeth of the final cutter, the ratio of the two pitches being the same as the ratio of the two degrees of reliefs, and in forming the shape of the relieved final milling cutter from. the said preliminary cutter whereby'the final cutter'is formed with a distorted shape ataxial planes of intersection but is adapted to cut the correct contour when rotated.

2. The herein described method of'shap; 'ing a spirally relieved milling cutter adapted to cut a predetermined contour other than a straight line and having helicoidal cutting faces, the method consisting in forming a preliminary milling cutter having at axial planes of intersection a shape the same or approximately the same as'the predetermined contour and' havi'ng its teeth provided with helicoidal cutting faces with a longitudinal pitchdifferent from the longitudinal pitch of the helicoidal cutting faces of the final cutter and provided with a degree of spiral reliefdifferent from the degree of spiral relief of the teeth of the final cutter, the ratio of. the two pitches being the same as the ratio of the two degrees of relief, and in-milling the final cutter wit the said preliminarycutter vvhile securing -he desired relief by effecting relative approaching and receding movements in correct relation to the helicoidal cutting faces whereby the final cutter' formed with a distorted shape at axial planes of intersection but is adapted to cut the correct contour when rotated.

3. The herein described method of shaping a spirally relieved milling cutter adapted to. cut a predetermined contour other than a straight line and having helicoidal cutting faces, the method consisting in forming a preliminary milling cutter having at axial planes of' intcrsection a shape the same or approximately the same as the |iredcterniiiual contour and having 100 its teeth provided with l-ielicoidal cutting faces with a longitudinal pitch smaller than the longitudinal pitch of the hclicoidal cut ting faces of the final cutter and provided with a degree of spiral rclicl' smaller than 105 the degree of spiral relief of thc fccflf of the final cutter, the ratio of the two pitches being the same as the ratio of the two degrees of reliefs. and in forming the shape of the relieved filial milling cutter from the 110 said prcliininaiy milli ig culfer whereby the final cutter is formed v vilh a distorted shape at axial planes of intersection but is adapted to cut the correct contour when rotated.

In testimony whereof 1 hereto aflix my 115 signature.

i innninncii MULLER. 

